Wire Reel Transmissive Photosensor for Reinforcing Bar Binding
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Solution Overview
Problem
Conventional reinforcing bar binding machines face issues with erroneous detection of wire reel rotation due to surface irregularities, limited sensor resolution, and inaccuracies in wire feed amount detection, leading to potential twist-off during binding.
Innovation Solution
A transmissive photosensor system with light-emitting and light-receiving elements on the binding machine and wire reel, utilizing light-transmitting portions on the reel to improve detection accuracy and resolution, allowing for precise rotational information and feed amount determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a reflective photosensor is used to detect rotation of the wire reel, then the detection system can identify wire type and control feed/torsion, but surface irregularities (stepped portions, sand, dust) cause erroneous detection and voltage fluctuations
Solution Approach 1:
The patent replaces the reflective photosensor system with a transmissive photosensor system. Instead of detecting reflected light from surface features, the new system uses a light source and photosensor positioned on opposite sides of the wire reel, detecting light transmission through the reel structure. This substitution eliminates sensitivity to surface irregularities while maintaining automatic detection capabilities.
Solution Approach 2:
The patent introduces light-transmitting portions as intermediaries in the detection system. These portions are specifically designed to transmit light from the light source through the wire reel to the photosensor, creating a reliable optical path that is not affected by surface conditions. The light-transmitting portions serve as a mediator between the light source and sensor, ensuring consistent detection.
2Reliability
If the area of white projections is increased to improve photosensor switching reliability, then detection reliability improves, but the shape of the wire reel is restricted and resolution cannot be increased
Solution Approach 1:
The patent inverts the detection approach by using light transmission instead of light reflection. Instead of increasing the area of reflective projections to improve reliability, the system uses light-transmitting portions whose geometry can be optimized for both reliability and resolution. The inversion of the optical principle allows simultaneous optimization of both parameters.
Solution Approach 2:
The patent changes the optical parameters of the detection system by switching from reflective to transmissive geometry. This parameter change allows the light-transmitting portions to be designed with optimal dimensions for both reliable detection and high resolution, freeing the wire reel shape from the restrictions imposed by reflective projection designs.
3Productivity
If the signal interval is set to 90° for rotation detection, then the detection system can identify rotation positions, but the ranges where rotation cannot be detected immediately after start and before stop are 90° each, causing maximum 180° error per binding
Solution Approach 1:
The patent segments the wire reel structure by providing multiple light-transmitting portions at different angular positions. This segmentation allows the photosensor to detect multiple discrete positions during rotation, reducing the undetected ranges. By dividing the detection task across multiple segments rather than relying on a single 90° signal interval, the system achieves both continuity and precision.
Solution Approach 2:
The patent adds angular dimensionality to the detection system by positioning light-transmitting portions at multiple angles around the wire reel. This multi-dimensional arrangement allows detection of rotation throughout the entire 360° cycle, eliminating the 90° blind zones present in single-interval systems and enabling continuous, high-precision rotation tracking.
4Device complexity
If conventional sensors with 90° signal intervals are used, then device complexity is reduced, but precise detection of wire reel rotation and detection of feed gear wear cannot be performed
Solution Approach 1:
The patent creates a universal detection system where the transmissive photosensor configuration serves multiple functions: detecting wire reel rotation, determining wire feed amount, and monitoring feed gear wear. By designing a multi-functional system based on light transmission, the patent achieves high precision across multiple measurement tasks without proportionally increasing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances detection accuracy and resolution, reducing errors in wire feed amount and preventing twist-off by directly detecting light through the light-transmitting portions, regardless of surface irregularities, and enabling precise control of wire feed and torsion torque.
Implementation Method 1
a transmissive photosensor having a light-emitting element on one of both side walls of the housing chamber and a light-receiving element on the other of both side walls; a plurality of light-transmitting portions formed on the wire reel and for transmitting light emitted from the light-emitting element
Data Source
AI summary
A wire reel is detachably provided in a housing chamber of a binding machine body which binds a reinforcing bar. The wire reel includes a cylindrical hub portion which winds a wire, and a pair of parallel flanges overhanging outward from both external peripheral ends of the hub portions. A side wall inside the hub portion is formed of light-transmitting portions which allow the light from a transmissive photosensor provided in the binding machine body to be transmitted therethrough.